Cross-linked polyethylene foam insulation for window and door frames

ABSTRACT

There is a frame insulator that covers a window or door frame. A door or window has one or more panels that are supported by frame members. The frame members have interior surfaces and exterior surfaces. The one or more panels are mounted on the frame members. The interior surfaces or the exterior surfaces or both are enclosed by sheets of cross-linked polyethylene foam extending adjacent to the one or more panels and forming frame insulators.

TECHNICAL FIELD

Insulation for window and door frames.

BACKGROUND

Window and door frames are often a source of heat transfer through thewindow or door. In the winter, heat may escape an interior space throughthe frames. In the summer, heat may enter the interior space. Aluminumframes may be particularly prone to either heat loss or gain. There aredrawbacks at current attempts to insulate window or door frames toreduce heat transfer. For example, rubber weather stripping can damagepaint or leave a sticky residue when they are removed. Weather strippingcan also be difficult to install. Other custom-made insulationtechniques can be expensive or time consuming to install. For example,painting over the frame may have only nominal insulating effects.

SUMMARY

In an embodiment there is a window or door having one or more panelssupported by frame members, the frame members have interior surfaces andexterior surfaces, the one or more panels are mounted on the framemembers, the interior surfaces or the exterior surfaces or both areenclosed by sheets of cross-linked polyethylene foam extending adjacentto the one or more panels and forming frame insulators.

In various embodiments, there may be included any one or more of thefollowing features: frame insulators include co-planar surfaces meetingat junctions, and the sheets of cross-linked polyethylene foam havematching tapers at the junctions, matching tapers comprising mitrejoints, the frame insulators including surfaces meeting at right anglesand sheets of the cross-linked polyethylene foam that line the surfacesthat meet at right angles forming butt joints, the frame members beingformed of one of wood, metal and plastic, the cross-linked polyethylenefoam having a density between 25 and 200 kg/m³, the one or more panelsare multiple transparent panes, and the frame members include at leastone member between two transparent panes of the multiple transparentpanes, the cross-linked polyethylene foam enclosing the at least onemember extending between the two transparent panes, the cross-linkedpolyethylene foam further comprises a U-shape and is flush with the atleast one member, the U-shape comprises multiple sheets of cross-linkedpolyethylene foam glued together, the frame members including outerframe members adjacent to a structure in which the window is placed, thecross-linked polyethylene foam covering the outer frame membersextending between the structure and the one or more transparent panes,the cross-linked polyethylene foam further comprises an L-shape and isflush with the outer frame members, the L-shape comprises two sheets ofcross-linked polyethylene foam glued together, and all the exteriorsurfaces on the frame of the window or door are covered by sheets ofcross-linked polyethylene foam, a window in which one or more panels areone or more window panes mounted between the exterior surfaces andinterior surfaces, and a door in which the one or more panels is a doorpanel.

These and other aspects of the device and method are set out in theclaims.

BRIEF DESCRIPTION OF THE FIGURES

Embodiments will now be described with reference to the figures, inwhich like reference characters denote like elements, by way of example,and in which:

FIG. 1A is a side view of a prior art window frame;

FIG. 1B is cross section of the window frame in FIG. 1A through the lineA-A;

FIG. 2 is a side view of a window frame with sheets of cross-linkedpolyethylene foam covering the frame;

FIG. 3 is a cross-section of the window frame in FIG. 2 through the lineB-B;

FIG. 4 is a top view of a collection of sheets of cross-linkedpolyethylene foam;

FIG. 5 is a top view of sheets of cross-linked polyethylene foam forminga frame insulator;

FIG. 6 is a side view of the sheets of cross-linked polyethylene foam ofFIG. 5;

FIG. 7 is an end view of the sheets of cross-linked polyethylene foam ofFIG. 5;

FIG. 8 is a side view of a door frame with sheets of cross-linkedpolyethylene foam covering the frame;

FIG. 9 is a top view of a pair of sheets of cross-linked polyethylenefoam;

FIG. 10 is a side view of the sheets of cross-linked polyethylene foamof FIG. 9; and

FIG. 11 is an end view of the sheets of cross-linked polyethylene foamof FIG. 9.

DETAILED DESCRIPTION

FIG. 1A is a front view of a prior art window 10. The window comprisesframe members 12A-12L. The frame members may be formed of any suitablematerial such as wood, metal or plastic. In an example, the framemembers are formed of aluminum. The window frame including multiplemembers may be formed as a single piece, or frame members may be formedof multiple pieces. Regardless of the precise construction, for thepurpose of this document a frame member is considered to be a portion ofthe frame between two intersections or corners of the frame.

Between the frame members are panels, which in this embodiment aretransparent window panes 14A, 14B, 14C and 14D. The frame members 12A to12L, have interior surfaces 20 and exterior surfaces 22 as shown in FIG.1B.

A structure 16 in which the window 10 is placed is shown adjacent toleft and bottom sides of the window of FIG. 1A, the left side of thewindow comprising frame members 12C and 12H and the bottom side of thewindow comprising frame members 12K and 12L. One example of thestructure 16 in which the window could be placed, as shown in FIG. 1A,is a wall. Another example is a door. The wall 16 could also be presentat the top and tight sides of the window, or the window could continuefurther to the top or right. A window may be composed of one or moretransparent frames.

FIG. 1B is a top view of a cross section of the left side of the windowof FIG. 1A. This shows the relation between the frame members and windowpanes more clearly. The window shown is single glazed but everythingdescribed in this document also applies to double or triple, etc.,glazed windows. The frame members shown here are hollow aluminum framemembers but everything in this document also applies to solid framemembers and to frame members of different materials.

FIGS. 2 and 3 show the window 10 insulated with sheets of cross-linkedpolyethylene foam. The window has four transparent panes 14A to 14Dsupported by frame members 12A to 12L (FIG. 1A). The panes 14A to 14Dare mounted between the exterior surfaces 22 and interior surfaces 20(FIG. 3) of the frame members. As shown in FIG. 3, the interior surfaces20 are enclosed by sheets of cross-linked polyethylene foam extendingadjacent to the transparent panes 14A to 14D and forming frameinsulators 18A to 18L. The exterior surfaces of the frames mayalternatively, or additionally, be enclosed by sheets of cross-linkedpolyethylene foam in the same manner.

The frame insulators 18A to 18L include co-planar surfaces meeting atjunctions as shown for example where frame insulators 18D, 18F, 18G and18I meet as shown in FIG. 2, and the sheets of cross-linked polyethylenefoam have matching tapers 24 at the junctions. The tapers 24 as shown inFIGS. 2 and 4 are at 45 degrees and form mitre joints. However, it willbe understood that different taper angle can be used as long as theadjacent tapers are flush with each other. The tapers need not be formedusing straight lines. By having flush tapered surfaces, gaps between thecross-linked polyethylene foam sheets are eliminated, which assists inreducing heat transfer through the window frames.

As shown in FIG. 2, the frame members include frame members that extendbetween two transparent panes of multiple transparent panes, forexample, frame 12D (FIG. 1A). The frame insulator 18D encloses andinsulates the frame 12D between the two transparent panes 14A and 14B.In this case, the frame insulator 18D further comprises a U-shape and isflush with the frame member 12D. The U-shape comprises multiple sheets26, 28, 30 (FIG. 5) of cross-linked polyethylene foam glued together.

As shown in FIGS. 5-7, the frame insulator 18D includes sheets 26, 28and 30 meeting at right angles. The sheets 26, 28 and 30 of thecross-linked polyethylene foam that line the surfaces that meet at rightangles form butt joints 32. Frame insulator 18D is used as an exampleframe insulator made from three sheets of foam, which is shown in moredetail in FIG. 5. Similarly, each of the frame insulators 18A, 18B, 18D,18E, 18F, 18G, 18I and 18J may also be formed from three sheets such as26, 28 and 30 (FIG. 3) that meet at right angles and form butt joints32. The joints may be glued together. The frame insulators may also beformed from more than three sheets if the frame has different shapes.The frame insulator may be constructed or assembled to have manydifferent shapes depending on the shape of the frame to which it ismounted.

As shown in FIG. 3, frame insulator 18C covers outer frame membersadjacent to the structure 16 in which the window is placed. Frameinsulators 18H, 18K and 18L are placed in a similar manner and have asimilar structure to frame insulator 18C and are also made from twosheets joined together. The frame insulators covering the outer framemembers extend between the structure 16 and the one or more transparentpanes. The frame insulators 18C, 18H, 18K and 18L form an L-shape andare flush with the outer frame members and lie adjacent to the structure16. Frame insulators 18C, 18H, 18K and 18L may be formed from twosurfaces 34, 36 (FIG. 3) that meet at right angles that form a buttjoint. Although only frame insulator 18C is shown in FIG. 3, the otherframe insulators 18H, 18K and 18L may be formed in the same manner. Thetwo sheets of cross-linked polyethylene foam may be glued together toform the butt joint.

As shown in FIG. 2, all of the interior surfaces on the frame of thewindow are covered by sheets of cross-linked polyethylene foam.Similarly, all of the exterior surfaces of the frame of the window maybe covered by sheets of cross-linked polyethylene foam in the samemanner.

FIGS. 8-11 show an embodiment in which frame insulators 18M, 18N and 18Qare placed on a door frame 50. There is a panel 42, which in thisembodiment is a door panel with a door handle 44. The principles ofapplication of the frame insulators is similar to those in theembodiments shown in FIGS. 2-7. The door frame 50 as shown in FIG. 8 isadjacent to structure 16, such as a wall. The frame insulators 18M, 18Nand 18Q are placed over frame members (not shown) of the door frame. Thedoor may open inwardly or outwardly and the frame insulators are placedin a manner that they do not interfere with the door opening or closing.The frame insulators 18M, 18N, and 18Q are tapered where they meet attapers 24 and form mitre joints. As shown in FIGS. 9-11, the frameinsulator 18M is made from two sheets 38 and 40 of cross-linkedpolyethylene foam that may be glued together to form the butt joints ina similar manner to frame insulator 18C as shown in FIG. 3. The frameinsulators 18N and 18Q may be formed in the same manner as frameinsulator 18M.

In the embodiments described herein, the cross-linked polyethylene foammay be used as insulation to cover the interior surfaces or exteriorsurfaces of a window or door frame where there is a temperaturedifference between opposite sides of the window or door. For example,the interior surfaces may be inside of a structure and the exteriorsurface may be outside of a structure. For example, in winter, it may bebeneficial to have cross-linked polyethylene foam on one of, or both of,the interior and exterior surfaces of the frame in order to retain heat.In the summer, it may be beneficial for the frames to be covered inorder to keep heat out of a cooler interior. The cross-linkedpolyethylene foam may provide an insulative benefit on any windows ordoors where there is a temperature difference on opposite sides.Although the terms interior and exterior surfaces are used, the termsare used for ease of reference to denote opposite ends of the window ordoor. It is not necessary for one side of the window or door to beinside and the other side to be outside.

Preferably, the frame insulators will be flush with the frame by havingmatching shaped surfaces, but open spaces between the frame and frameinsulators may also be present. The frame insulators may be pressed fitinto place on the window frame. Glue or other securing technique may bealternatively or additionally be used to hold the foam in place on thewindow frame. The foam may form a seal around the window frame. Byforming a seal, the cross-linked polyethylene foam may be less likely toleak than alternative insulating techniques. The foam is also safe andstable, as well as impact absorbing. There is no need to paint over theframe once it has been sealed with foam. Different colours of foam maybe selected depending on the desired aesthetic.

The foam may also be custom-designed to fit the shape of the frame.Various different numbers of connected pieces of cross-linkedpolyethylene foam can be used. The sheets of foam may be connected toeach other by other means other than glue. In some embodiments, a sprayadhesive, such as Super 77™, may be used to glue the sheets ofcross-linked polyethylene foam together. The same glue may be used toattach the foam to the window frames. The cross-linked polyethylene foammay assist in preventing moisture from entering the frame. The frameinsulators in some embodiments may be custom designed to have aparticular shape. For example, the frame insulators may be made from asingle custom-designed sheet of cross-linked polyethylene foam which isdesigned to match the shape of the frame.

The cross-linked polyethylene foam may be foam such as is supplied byPalziv North America. In a preferred embodiment, the cross-linkedpolyethylene foam may have the following composition:

Substance Substance (Abbreviation) (Chemical name) Cas # PHR LDPEPolyethylene 9002-88-4 100 DCP Dicumyl Peroxide 80-43-3 <1 ADCAAzodicarbonamide 123-77-3 <20 MB Organic Pigment <3

The cross-linked polyethylene foam sheets may have a density between 25and 200 kg/m³. In a preferred embodiment, the foam sheets may have adensity of approximately 64.07 kg/m³. In other embodiments, the densityof the foam sheets may be within 10% or 20% of 64.07 kg/m³.

Immaterial modifications may be made to the embodiments described herewithout departing from what is covered by the claims.

In the claims, the word “comprising” is used in its inclusive sense anddoes not exclude other elements being present. The indefinite articles“a” and “an” before a claim feature do not exclude more than one of thefeature being present. Each one of the individual features describedhere may be used in one or more embodiments and is not, by virtue onlyof being described here, to be construed as essential to all embodimentsas defined by the claims.

1. A window or door having one or more panels supported by framemembers, the frame members having interior surfaces and exteriorsurfaces, the one or more panels being mounted on the frame members, theinterior surfaces or the exterior surfaces or both being enclosed bypre-fabricated sheets of cross-linked polyethylene foam extendingadjacent to the one or more panels and forming frame insulators.
 2. Thewindow or door of claim 1 in which the frame insulators includeco-planar surfaces meeting at junctions, and the sheets of cross-linkedpolyethylene foam have matching tapers at the junctions.
 3. The windowor door of claim 2 in which the matching tapers comprise mitre joints.4. The window or door of claim 1 in which the frame insulators includesurfaces meeting at right angles and sheets of the cross-linkedpolyethylene foam that line the surfaces that meet at right angles formbutt joints.
 5. The window or door of claim 1 in which the frame membersare formed of wood.
 6. The window or door of claim 1 in which the framemembers are formed of metal.
 7. The window or door of claim 1 in whichthe frame members are formed of plastic.
 8. The window or door of claim1 in which the cross-linked polyethylene foam has a density between 25and 200 kg/m³.
 9. The window or door of claim 1 further comprising awindow, and in which one or more panels are one or more window panesmounted between the exterior surfaces and interior surfaces.
 10. Thewindow of claim 9 in which the one or more window panes are multipletransparent panes, and the frame members include at least one memberbetween two transparent panes of the multiple transparent panes, thecross-linked polyethylene foam enclosing the at least one memberextending between the two transparent panes.
 11. The window of claim 10in which the cross-linked polyethylene foam further comprises a U-shapeand is flush with the at least one member.
 12. The window of claim 11 inwhich the U-shape comprises multiple sheets of cross-linked polyethylenefoam glued together.
 13. The window or door of claim 10 in which theframe members include outer frame members adjacent to a structure inwhich the door or window is placed, the cross-linked polyethylene foamcovering the outer frame members extending between the structure and theone or more transparent panes.
 14. The window or door of claim 13 inwhich the cross-linked polyethylene foam further comprises an L-shapeand is flush with the outer frame members.
 15. The window or door ofclaim 14 in which the L-shape comprises two sheets of cross-linkedpolyethylene foam glued together.
 16. The window or door of claim 1 inwhich all the exterior surfaces on the frame are covered by sheets ofcross-linked polyethylene foam.
 17. The window or door of claim 1 inwhich the window or door further comprises a door and the one or morepane further comprises a door panel.
 18. A window or door having one ormore panels supported by frame members, the frame members havinginterior surfaces and exterior surfaces, the one or more panels beingmounted on the frame members, the interior surfaces or the exteriorsurfaces or both being enclosed by pre-fabricated sheets of cross-linkedpolyethylene foam extending adjacent to the one or more panels andforming frame insulators, wherein the frame insulators include co-planarsurfaces meeting at junctions, wherein the frame insulators includesurfaces meeting at right angles and sheets of the cross-linkedpolyethylene foam that line the surfaces that meet at right angles formbutt joints, and wherein the sheets of cross-linked polyethylene foamhave matching tapers at the junctions.
 19. A window or door having oneor more panels supported by frame members, the frame members havinginterior surfaces and exterior surfaces, the one or more panels beingmounted on the frame members, the interior surfaces or the exteriorsurfaces or both being enclosed by pre-fabricated sheets of cross-linkedpolyethylene foam extending adjacent to the one or more panels andforming frame insulators, further comprising a window, wherein the oneor more panels are one or more window panes mounted between the exteriorsurfaces and interior surfaces, wherein the one or more window panes aremultiple transparent panes, wherein the frame members include outerframe members adjacent to a structure which the door or window isplaced, wherein the frame members include at least one member betweentwo transparent panes of the multiple transparent panes, wherein thecross-linked polyethylene foam covers the outer frame members extendingbetween the structure and the one or more transparent panes of themultiple transparent panes, and wherein the cross-linked polyethylenefoam encloses the at least one member extending between the twotransparent panes.